Great Wall Sailor (2006 year). Instruction - part 2

 

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Great Wall Sailor (2006 year). Instruction - part 2

 

 

MT-3

Troubleshooting

Gear Box 

Troubleshooting

Non-use of clutch

Non-full separation of clutch

Severely warned tooth rings of synchronizing

fittings

Over-hard locating spring

Use the right driving approach

Checking for adjustment

Change

Change

Difficulty in gear engagement

Over-low oil level

Lubricating oil of inferior quality

Non-timely oil change

Unsuitable axial location or clearance of gears

Bearing damage

Burr or collision on gear

Add oil to the specified level

Change it with the specified oil

Change the oil and damaged parts

Check for adjustment

Change

Repair or change the gear

Oil leakage, oil penetration

Oil added above the specified level

Loss or missing of bolts

Vent plug trouble

Sealing element damage

Adjust oil to the given level

Reassembling or fasten the bolt according to

the specified torque

Change

Change

Damage of synchronizer

Overexert in gear shift

Non-use of clutch

Damage on spring collar of synchronizer

Incorrect mounting of drive shaft

Change

Use the right driving approach

Change

Check for adjustment

Non-engagement of gear

Trouble in controlling mechanism

Incorrect assembling the locating spring or

steel ball

Invalidation of locating spring

Severely worn gear sleeve or fork groove

Seriously worn toggle fork

Check for adjustment

Reassembly

Change

Change

Change

Burning bearing, burning gear

Over-low oil level

Inferior lubricating grease

Non-timely oil change, over-dirty oil

Inter-use of differential oil or usage of

additive

Change damaged parts and add oil

Change the damaged parts and lubricating oil

Change damaged parts and lubricating oil

Change damaged parts and lubricating oil

Difficult in gear disengagement

Spring invalidation of synchronizer

Warn inner groove of tooth ring of synchronizer

Tooth ring of synchronizer choked on conical

face

Toggle fork deformation or toggle fork axle

deformation

Severely worn toggle fork

Change

Change

Change

Change

Change

Methods for troubleshooting

Over-loud or abnormal noise

Common Failures

Causes

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MT-4

Gearbox

Dismantle of Gear Box

3.

Tear down the shifting ball of gear change lever

Loose the locking nuts by dextroroting the ball.

4.

Tear down the glove box

Dismantle the four bolts of the glove box and put the glove box

into the suitable place.

5.

Tear down the dust cover.

6.

Tear down the gear change lever.

7.

Raise the vehicle to discharge the oil in gearbox.

Warning: the reliability of vehicle shall be verified.

8.

Tear down the drive shaft.

(See page PR-5)

9.

Tear down the odometer sensor and the plugging

elements of backup switch

10.

Tear down the vent pipe.

Tear down the heading exhaust pipe from branch exhaust pipe

Dismantle of gearbox

1.

Disconnect the cathode wire from the cathode of storage

cell.

2.

Tear down the setting bolts of fan cover.

Tear down 4

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MT-5

Gearbox

Dismantle of Gear Box

4WD

11.

Tear down the wheel-brake cylinder of clutch.

(a)

Dismantle the setting bolts of the wheel-brake cylinder of

clutch with spanner.

(b)

Hang the wheel-brake cylinder with a thread on the side

of engine without oscillation.

Remark: Do not disconnect the pipeline of the wheel-brake

cylinder.

12.

Tear down the pawl washer and bracket of the rear part

of gearbox:

Two-wheel driving:

(a)

Dismantle the four bracket bolts (skip over this process

for the wielding structure).

(b) 

Lift the engine with jack to raise the gearbox a little.

(c) 

Dismantle the pawl washer from the rear part of gearbox.

Four-wheel driving:

Dismantle the bolts from the pawl washer and bracket of the

rear part of gearbox to tear down the pawl washer and bracket.

13.

Insert the wooden plate between the bottom frame and

the beam.

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MT-6

Gearbox

Dismantle of Gear Box

4WD

14. Dismantle the eight bolts that fasten the beam of gearbox.

15. Tear down the starter

Put the starter on the side of engine.

16. Dismantle the bolts of clutch frame and bracket (wrapping

angle).

17. Tear down the remaining bolts of gear box

18. Tear down the gear box

(a)

Pull out the gear box in backward direction;

(b) Put down the engine at the front and tear down the

gearbox from the vehicle.

Notice: be careful not to damage the dust cover of

expansion shell.

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MT-7

Gear Box

Mount of Gear Box

Mount of gear box

1.

Put down the gearbox at the mounting place.

2.

Mount the bolts of gearbox, clutch bracket and starter.

Tightening moment:

(a)  Setting bolt of gear box (82

10)Nm

(b)  Enforcement plate bolt  (37

5)Nm

(c)  starter bolt  (39

5)Nm

Notice: the bolts of gear box and clutch shall be mounted

with the clutch pipe clip together.

3.

Mount the pawl washer and bracket of gearbox

Two-gear driving:

(a)  Mount the gearbox pawl washer and fasten the relative

bolts.

Tightening moment: 23

3)Nm

(b)  Lift the rear part of engine with jack and wooden block so

that the gearbox is raised a little.

(c)  Mount the bracket of gear box on beam and fasten the

relevant bolts (this process may skip over in wielding

structure)

Tightening moment

(23 3)Nm

(d) Connect the gearbox bracket and supporter with bolts,

then tighten the bolts.

Tightening moment: (23

3)Nm

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MT-8

Gear Box

Mount of Gear Box

4WD:

(a)

Mount the bracket and supporter of leg washers of rear

         engine in 4WD vehicle;(SF)

(b)

Mount and tighten the third beam of 4WD vehicle. (SF)

4. 

Remove the wooden spill.

5.

Mount exhaust pipe.

Mount the exhaust pipe on the branch exhaust pipe.

Tightening moment

(62 3)Nm

6.

Mount the wheel-brake cylinder of clutch.

Tightening moment

(18 2)Nm

7.

Mount odometer sensor and plugging elements of backup

switch.

8.

Connect the drive shaft.

(See page PR-12)

9.

Add oil into the gearbox.

Lubricating oil grade: GL-5 85W/90

Volume: 2.4L(dry)

Remark: the Tightening moment of oil filling/draining

plug: (30

50)Nm

4WD

4WD

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MT-9

Gear Box

Mount of Gear Box

10.

Drop the vehicle.

11.

Mount the dust cover and gear change lever.

12.

Mount storage box.

13.

Mount the instruction ball, and

14.

Mount the fan cover and fasten the bolts.

Mount on them and screw up the four bolts.

15.

Connect the cell cable to the cathode of storage cell; and

16.

Conduct the load test

Check whether there is abnormal noise and whether the

operation is stable.

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MT-10

Gearbox

Disassembly of Gear Box

Disassembly of Gear Box

1.

Tear down the separation toggle fork and separation

bearing.

2.

Tear down the backup switch, the driven gear of

speedometer.

3.

Tear down the clutch from the gearbox frame.

Take apart the nine boits.

4.

Tear down bolts of locating spring of the five-speed

toggle fork, locating spring and locking ball.

(a)  Dismantle the bolts from the rear cover with the torque

socket spanner.

(b)  Take out the spring and locking ball with magnetic rod.

5.

Tear down the operating seat of gear change lever.

(a)  Dismantle the setting bolts of the operating seat of gear

change lever.

(b) Take away the operating seat lightly and put it at the

suitable place.

6.

Tear down axial locating pin assembly of shifting gear.

7.

Tear down the fastening nuts of extension frame.

(a)  Tear down the fixing bolts of gearshift shaft.

(b)  Tear down the fastening nuts of expansion shell.

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MT-11

Gearbox

Disassembly of Gear Box

(c)   Dismantle the nuts of the four-gear driven extension fram.

(d)  Tap the extension frame lightly with rubber hammer to tear

down the selective gearshift shaft and selective rocker

arm.

8.

Tear down front cover.

Dismantle the eight bolts and front cover and axial oil seal.

9.

Tear down the input shaft, axial/bearing open ring and

countershaft bearing open ring.

10. Dismantle the gearbox frame from the central link plate,

(a)  Put the gearbox straightly as shown in the drawing.

(b)  Tap out the gearbox frame out carefully with the rubber

hammer. And

(c)  Pull out the gearbox frame out from the central link plate

as the drawing shows

4WD

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MT-12

Gearbox

Disassembly of Gear Box

11. Grip the central link plate in the table vice,

(a)   Use two clutch bolts, washers and suitable nuts as shown

in the drawing.

Remark: mount the washer in the reverse direction, increase

and decrease the washer quantity to flush the bolts terminal

with the external face of the washer.

(b)   Grip the central link plate in the table vice.

12. Tear down the locating spring bolts, locating spring and

locking ball,

(a)   Dismantle each locating spring bolts with the torque socket

spanner.

(b)  Take out the toggle fork axles of the first, second, third,

fourth and reverse as well as the axial locating spring and

locking ball of the fifth-gear toggle fork.

13. Tear down the axial retainer ring of the gearshift fork

Tap the axial retainer ring of gearshift fork lightly with two

screwdrivers and one hammer.

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MT-13

Gearbox

Disassembly of Gear Box

14. Tear down the five-speed gearshift toggle fork,

(a)  Punch out the spring pin with impact head and hammer.

(b)  Tap the five-speed gearshift fork until take it out.

Notice: It must be the neutral location this time.

15. Tear down the guiding module of the five-speed gear-

shift and five-speed reverse shift fork axle.

(a)  Take out the inter-locking steel ball from the guiding

module of the fifth reverse shift-shaft.

(b)  Tear down the fifth reverse shift guiding module and fifth

reverse shift fork axle.

16. Take out the five-speed gearshift fork axle

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MT-14

Gearbox

Disassembly of Gear Box

17. Tear down the reverse shift fork axle, reverse rocker

arm, reverse toggle lever and toggle block

(a)  Tap out the spring pin with the nail punch and hammer.

(b)   Take out the interlocking ball and interlocking guidepost

between the reverse shift fork axle and the five-speed

gearshift fork axle.

(c)  Tear down the reverse shift fork axle, and

(d)  Tear down the reverse rocker arm and yoke block.

18. Tear down the first-second-speed gearshift fork axle.

(a)  Take out the interlock pin and interlock guide post between

the reverse shift fork axle and the five-speed gearshift fork

axle.

(b)  Dismantle the locating bolts of the toggle fork of the first-

second-speed gearshift toggle fork.

(c)  Dismantle the fork axis of the first-second-speed gearshift.

(d)  Take out the short interlock pin between the first-second-

speed gearshift fork axle and the third-fourth-speed gear-

shift fork axle

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MT-15

 Gearbox 

 Disassembly of Gear Box

19. Tear down the third-fourth-speed gearshift fork axle and

the toggle forks of first-second speed gear and third-

fourth speed gear.

(a)  Tap out the spring pin with the nail punch and hammer.

(b)  Tear down the toggle forks of the third-fourth and first-

second-speed gearshift.

20. Tear down the coupling gear, synchronizer, gear cluster,

thrust washer and needle bearing of the five-speed

gearshift

(a)   Tap down the retainer ring of the rear countershaft with

two screwdrivers and one hammer.

(b)   Tear down the synchronizer assembly, coupling gear and

gear cluster of the five-speed gearshift. And

(c)  Dismantle the five-speed needle bearing.

21. Tear down the thrust washer and five-speed lock ball.

(a)  Tear down the thrust washer of five-speed gear.

(b)  Take out the lock ball with magnetic rod.

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MT-16

 Gearbox

Disassembly of Gear Box

22. Tear down the reverse rocker arm bracket

Dismantle the two bolts and the reverse rocker arm bracket.

23. Tear down the reverse idle gear and reverse idle gear

axle

(a)  Dismantle the setting bolts of idle gear and the pressing

plate of reverse idle gear axle.

(b)  Dismantle the reverse idle gear and the reverse idle gear

shaft.

24. Take down the bearing baffle of the output shaft.

(a) Dismantle the four bolts with torque socket spanner.

(b) Take down the bearing baffle of the output shaft.

25. Dismantle the intermediate-gear shaft.

(a)  Pry out the split ring of the rear bearing of the intermediate-

gear shaft with the split-ring-type pliers.

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MT-17

 Gearbox

Disassembly of Gear Box

SST

push down

to close

(b) Taker apart the rear bearing of intermediate shaft with

SST tool and wrench.

(c) Take down the intermediate shaft.

26. Tear down the input shaft

Tear down the bearing with 13 needles and synchronizing ring

from the input shaft.

27. Tear down the output shaft

(a)   Dismantle the stop ring from the output bearing with split-

ring-type pliers.

(b)   Tap lightly the central link plate with rubber hammer while

pulling the output shaft instructionly to tear down the output

shaft.

28. Check the back-up lamp switch

Check the terminal connection, when the switch is pressed

down, as shown in the drawing, it is connected, otherwise is

disconnected, in case the switch is not in conformity with this,

it shall be changed.

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MT-18

Gearbox

Input Shaft Assembly (Element Drawing, Inspection On Synchronizing Ring, and BearingChange)

Input Shaft Assembly

Inspection  on Synchronizing Ring

1.

Run the synchronizing ring and put it into the assembly

to check its stopping performance

2. Check the clearance between the rear face of

synchronizing ring and the gear.

Standard clearance:

Tung tooth

(11.6)mm

Upper tooth

(1.51.8)mm

Limit clearance

0.8mm

Bearing Change

1.

Tear down the input shaft bearing with the pressure

machine.

retainer ring

bearing stop ring

bearing

input shaft

needle bearing

synchronizing ring

element drawing

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